LPE Series Operation Manual P3 - EP

LPE Series Operation Manual P3 - EP
LPE SERIES
DC-AC Sinewave Inverter
and LPES Shelves
Operation Manual
Manual Part Number 800586001
LPE Series
KEY CONTACT INFORMATION ..................................................................................................................................3
APPLICATION SUPPORT, CUSTOMER SERVICE, REPAIRS...................................................................................3
INTRODUCTION TO THE LPE SERIES ......................................................................................................................4
FEATURES......................................................................................................................................................................4
SPECIFICATION FOR THE LPE SERIES ....................................................................................................................5
SPECIFICATION FOR THE LPE SERIES (CONTINUED) ........................................................................................6
THEORY OF OPERATION .............................................................................................................................................7
INVERTER APPLICATIONS .........................................................................................................................................7
LPE OPERATION .............................................................................................................................................................8
HOT BUS PLUG-IN ........................................................................................................................................................8
REMOTE CONTROL ......................................................................................................................................................8
FAULT ISOLATION / N+1 REDUNDANCY.................................................................................................................8
THERMAL PROTECTION .............................................................................................................................................8
OUTPUT PROTECTION.................................................................................................................................................8
CURRENT SHARING.....................................................................................................................................................8
LPE ELECTRICAL SYSTEM OVERVIEW ..................................................................................................................9
DC/DC CONVERTER .....................................................................................................................................................9
DC/AC INVERTER .......................................................................................................................................................10
EMI INPUT FILTER......................................................................................................................................................11
EMI OUTPUT FILTER..................................................................................................................................................11
FIGURE 1: LPE INVERTER FUNCTIONAL BLOCK DIAGRAM .............................................................................................11
LPE PIN-OUT AND INSTALLATION..........................................................................................................................12
REAR CONNECTOR PINOUTS...................................................................................................................................12
TABLE 1 - REAR CONNECTOR PINOUTS ...........................................................................................................................12
FIGURE 2: LPE REAR CONNECTOR VIEW ........................................................................................................................12
INSTALLATION ...........................................................................................................................................................12
LPES SERIES SHELVES................................................................................................................................................13
INTRODUCTION TO THE LPES SERIES ...................................................................................................................13
MECHANICAL .............................................................................................................................................................13
ELECTRICAL................................................................................................................................................................13
GROUNDING................................................................................................................................................................14
SIGNAL CONNECTOR PIN ASSIGNMENTS ............................................................................................................15
APPENDIX A....................................................................................................................................................................16
LPE OUTLINE DRAWING...........................................................................................................................................16
APPENDIX B ....................................................................................................................................................................17
LPES OUTLINE DRAWING.........................................................................................................................................17
REVISION HISTORY .....................................................................................................................................................18
800586001 Operation Manual Rev A
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LPE Series
KEY CONTACT INFORMATION
APPLICATION SUPPORT, CUSTOMER SERVICE, REPAIRS
Americas:
TDI Power – Hackettstown, NJ
36 Newberg Road
Hackettstown, NJ 07840
Phone: +1.908.850.5088 Fax: +1.908.850.1607
Europe, Middle East, Africa:
TDI Power – Europe
P.O. Box 1
Ballincollig, Co. Cork, Ireland
Phone: +44 790 990 6060
Asia:
TDI Power – China
5th Floor, Dazu Control Building
16 Shihua Road, Futian Free Trade Zone
Futian District, Shenzhen 518038, PRC
Phone: +86 (0) 755 8386 7666
800586001 Operation Manual Rev A
Fax: +86 (0) 755 8273 9766
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LPE Series
INTRODUCTION TO THE LPE SERIES
This Operation Manual provides a general description of the LPE series Sine-wave Inverter
designed to provide reliable AC power from a DC source. A battery plant (DC source) will provide
the input voltage for the Inverter.
Inverters are used to convert DC voltages to sinusoidal AC voltages for conventional AC
applications (120 VAC @ 60 Hz or 220 VAC @ 50 Hz). The LPE series Inverter is an industrial
designed power supply that incorporates state-of-the-art electronics to provide high power density
and reliability in a compact unit.
The LPE Series Inverters, manufactured by TDI Power delivers a near perfect sine-wave from a
variety of DC sources. These low cost, solid state inverters utilize high frequency pulse width
modulation technology to synthesize a precision regulated sinusoidal output with less than 1% Total
Harmonic Distortion. The wide input range allows the inverter to operate within the charge and
discharge limits of any battery technology making it ideal for back-up UPS applications.
The LPE sine-wave inverter is ideal for use in telecom sites and customer premise equipment, fuel
cell, solar power applications, and for data centers. The LPE inverter delivers a fully isolated and
precision regulated output capable of powering loads with a power factor from zero lead to zero lag.
The ability to deliver high peak currents makes the LPE inverter ideal for driving non-linear loads
such as rectifiers or motors. Units are capable of parallel and synchronized operation. Multiple units
(up to 12) can be user configured for single or three phase output configuration. N+1 redundancy is
achieved with 2 or more inverters connected in parallel. The unit is lightweight (under 3 lbs.) and is
available in a modular, rack mount, or shelf mount enclosure.
FEATURES
Ø Hot-Bus Plug In
Ø Parallelable, supports N+1 Redundancy
Ø Scaleable From 500VA to 6kVA
Ø Failsafe - No Single Point Failure
Ø Demonstrated MTBF >600,000 Hours
Ø Various mounting schemes available
Ø Low Profile, High Density
Ø Full Power from -20 to +55°C
Ø 1Ø System Configuration, for 2Ø or 3Ø System Configurations, consult factory
Ø Powers Loads with power factors from zero lead to zero lag.
800586001 Operation Manual Rev A
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LPE Series
SPECIFICATION FOR THE LPE SERIES
LPE500 48VDC
LPE400 24VDC
Input
Nominal Input
Input range
Input UV turn-on
Input UV turn-off
Input OV turn-off
Input OV turn-on
Inrush Current Controlled
Maximum Input Current
at low line
-48 VDC
-40.5 VDC to -60 VDC
-41 VDC to -43 VDC
-38 VDC to -40 VDC
-62 VDC to -64 VDC
-57 VDC to -59 VDC
< 80 Amps peak
15A steady state.
30 A peak for 2 sec (during output
overload)
24 VDC
19 VDC to 30 VDC
19 VDC to 21 VDC
17 VDC to 19 VDC
30.5 VDC to 32.5 VDC
28 VDC to 30 VDC
< 80 Amps peak
25.4A
Output
Sinusoidal waveform with less than 1% THD Typical
120 VAC / 60 Hz or 220/230 VAC / 50 Hz
Voltage regulation better than 5%
Frequency controlled better than 0.25% stability
Fully Isolated Input to Output
DC content: 10 mV max
No preload required
Power Rating
Maximum Power, over
500VA
400VA
full temperature range
Maximum Rated Output
120 VAC Unit: 4.17 Amps (RMS)
120 VAC Unit: 3.33 Amps (RMS)
Current (Continuous)
220 VAC Unit: 2.27 Amps (RMS)
230 VAC Unit: 1.74 Amps (RMS)
Efficiency
85% Min. at Full Load, 86% typical
83% Min. at Full Load
Hold-up time
10ms min. @ 43 VDC
10ms min. @ 21 VDC
Peak Output Current Into 11.7 A (peak) Max. for 120 VAC
9.3 A (peak) Max. for 120 VAC
Nonlinear Load:
6.35 A (peak) Max. for 220 VAC
4.8 A (peak) Max. for 230 VAC
Output power factor:
Linear – Powers all loads with zero leading to zero lagging PF,
Nonlinear – Rectified loads with up to 2.8 Crest Factor at full load.
800586001 Operation Manual Rev A
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LPE Series
SPECIFICATION FOR THE LPE SERIES (continued)
EFFICIENCY
Standby Power: Under 30 Watts at No Load
PROTECTION
Input Undervoltage
Input Overvoltage
Output Overload
Output Short Circuit
Over Temperature
RELIABILITY
Demonstrated MTBF >600,000 Hours
Calculated MTBF: Consult Factory
800586001 Operation Manual Rev A
ENVIRONMENTAL
Cooling: internal fan
Operating Temp: -20° to +55°C (full power)
Storage Temp: -40° to +70°C
Humidity: 0-95% non-condensing
Safety Agency: UL, CUL, CB
MECHANICAL
Hot Swaps into LPES Series shelf
Weight: Under 3 lbs.
Size: 5.6” W x 1.5” H x 9.63” D
(See Appendix A - Outline Drawing)
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LPE Series
THEORY OF OPERATION
INVERTER APPLICATIONS
In its most basic form, an AC Power Supply converts DC input voltage into a regulated AC output.
This configuration is commonly known as a DC-AC Inverter – or more simply – an Inverter.
DC-Input
DC-AC
Inverter
AC-Output
Inverters are used to derive AC power from a DC bus. DC-AC Inverter technology offers options to
the power system architect. It offers an elegant, cost-effective approach for generating an AC bus
when:
*
*
*
*
*
*
No AC is available within the system
AC is not accessible within the system
The primary AC supply is experiencing frequent interruptions
The DC bus has built-in redundancy
The available AC is of an unacceptable configuration
Use of a DC bus is more convenient than routing AC throughout the system
TDI Power has the industry’s widest offering of “near-perfect sine-wave” DC-AC Inverters ranging in
size from 400 Watts to over 30,000 Watts. Available in a wide variety of shapes and sizes, we can
tailor the electrical and mechanical configurations to address almost any application. These low
cost, solid state inverters utilize high frequency pulse width modulation (PWM) technology to
“synthesize” a precision regulated sinusoidal output with typically less than 1% Total Harmonic
Distortion (THD).
Wide input ranges allow the Inverters to operate within the charge and discharge limits of any
battery technology, making them ideal for back-up UPS applications.
800586001 Operation Manual Rev A
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LPE Series
LPE OPERATION
HOT BUS PLUG-IN
The LPE series inverter is a true hot-swap module. The hot-swap plug-in feature is
facilitated via a turn on sequence guided by both software and hardware. Different length
pins on the connector ensure “Make First” and “Break Last” connections. Power-up
sequencing is then guided by a micro-controller in the control circuitry.
NOTE: The handle on the front panel is only meant to aid extraction of a module
from the shelf. This handle does not activate any switch to shut down the unit, nor
should this handle’s rotation be used to “seat” the module into the shelf.
REMOTE CONTROL
The LPE offers a remote on/off capability via pins B2 (-) and B3 (+) on Connector P100 for
the 120VAC models and via pins B2 (-) and C2 (+) for the 220/230VAC models (reference
Table 1, Rear connector Pin-outs on Page 12). B2 is referenced to the DC Input (negative)
terminal, but these two should never be connected externally as doing so bypasses a safety
critical fuse. Connecting these two pins to each other enables the LPE, disconnecting these
pins from each other disables the LPE. This connection can be made/broken through either
hardwire, dry contact, or open collector means. The open circuit voltage on these contacts
will be a maximum of 15V. The current through closed contacts will be will be less than
2mA. For proper operation during conduction, the saturation voltage between these
contacts must be less than 0.5V.
FAULT ISOLATION / N+1 REDUNDANCY
If a unit failure occurs when operated in parallel with other units, the potential exists where
the failed unit may load the other units with a short circuit or overload. To circumvent this,
the faulted unit will open relay K101, thus disconnecting the output from the other units. This
design feature enables true N+1 redundancy with glitch-free operation.
THERMAL PROTECTION
Thermal protection is achieved by monitoring the power converter elements within the
inverter. If the temperature reaches unsafe levels, the unit will be disabled internally until it
cools to an acceptable level. The unit will then re-start automatically.
OUTPUT PROTECTION
Although the inverter output is fully protected against external overload and short
circuit, external protection devices such as fuses, circuit breakers, etc. may be used.
CURRENT SHARING
Pin D3 on connecter P100 (reference Table 1, Rear Connector Pin-outs on Page 12) provides an
analog signal that allows current sharing between parallel units. For parallel operation all current
sharing signals from each unit must be connected together.
800586001 Operation Manual Rev A
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LPE Series
LPE ELECTRICAL SYSTEM OVERVIEW
A block diagram, highlighting the major functional elements of the LPE Inverter, is shown in
Figure 1 on Page 11.
The major functional elements of the LPE Inverter are listed below:
a)
b)
c)
d)
e)
f)
DC/DC Converter
DC/DC Control
DC/AC Inverter
DC/AC Control
EMI Input Filter
EMI Output Filter
A functional description of each major element follows:
DC/DC CONVERTER
The DC/DC Converter transforms the DC input voltage to an isolated DC link voltage.
The converter contains the following items:
a)
b)
c)
d)
e)
High Frequency Pulse Width Modulator Inverter
Transformer
Output filter
Over current protection circuitry
Inrush current protection circuitry
Ø The HF-PWM/I converts a DC voltage to a series of high frequency pulses.
Ø The transformer provides reinforced insulation between the low-level input voltage and
the AC output. A DC Link-bus is also created in order for the DC/AC Inverter to generate
the proper AC output voltage.
Ø The output filter reduces internal harmonics to an acceptable level prior to reaching the
DC/AC Inverter.
Ø The output DC/DC Converter output circuit (providing the link voltage) is protected by a
fuse (F103), providing fault isolation from the DC/AC Inverter. The input circuit is
protected by a fuse (F101) located in the negative bus return for 48V LPE and in the
positive bus for 24V LPE.
Ø Inrush current is limited by resistor R100 which, after the inrush pulse, gets shorted by
relay K100.
800586001 Operation Manual Rev A
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LPE Series
DC/DC CONTROL UNIT
This section controls the DC/DC Converter so the necessary DC-Link bus voltage is regulated over
all line and load conditions. This DC-Link bus provides the power the DC/AC Inverter converts to
the AC output.
The DC/DC Control consists of the following items:
a)
b)
c)
Front panel LED Indicators
Remote On/Off circuitry
Link-voltage control circuitry
Ø The Input indicator (Green LED) is activated when the input voltage is within a safe
operating range.
Ø The Fault indicator (bi-color Red/Green LED) is activated when any fault condition exists
as follows:
a)
b)
c)
d)
Synchronization error
DC-Link Over Voltage
Inverter Fault
Over temperature
DC/AC INVERTER
The DC/AC Inverter unit converts the DC link voltage to the required AC output voltage.
This unit contains the following items:
a) High frequency Pulse Width Modulator Inverter
b) Output filter
c) Control and Protection circuitry
Ø The DC/AC inverter and output filter convert the link voltage to a sinusoidal output
voltage.
Ø The output filter reduces high frequency harmonics to an acceptable level.
Ø Output circuitry is protected by fuse (F102).
DC/AC CONTROL
The DC/AC Control provides main control for the Inverter. Protection features are
incorporated to provide:
a)
b)
Output Overload and Short Circuit Protection
DC Link Over Voltage Protection
800586001 Operation Manual Rev A
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LPE Series
EMI INPUT FILTER
The EMI input filter protects the DC input source by attenuating the high frequency
harmonics that are generated by the power switching elements
EMI OUTPUT FILTER
The EMI output filter protects the output load by attenuating the high frequency harmonics
that are generated by the power switching elements from within the Inverter.
Figure 1: LPE Inverter Functional Block Diagram
800586001 Operation Manual Rev A
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LPE Series
LPE PIN-OUT AND INSTALLATION
The LPE set-up and installation is normally performed by LPES Series shelves. The user needs the
information in this section only when using the LPE500 Series Inverters without the LPES Series
shelves.
REAR CONNECTOR PINOUTS
Table 1 on Page 12 lists the functions for each Pin on the rear connector, Figure 2 on Page 12.
Depending on the AC Voltage of the module used, different combinations of pin assignments are used.
Function
Pin No.
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
P1, P2, P3
P4, P5, P6
P7
P8
P9
A2
A3
A4
A5
B2
B3
B4
B5
C2
C3
C4
C5
D2
D3
D4
D5
-DC Input Return (-)
+DC Input Power (+)
Safety Ground
AC Out Return (N)
AC Out Power (L)
Fault (+)
Reserved
Trigger Out 180°
Fault return (-)
Remote return (-)
Remote (+) (120)
Trigger Out 120°
Fault Signal (+)
Remote (+) (220)
Enable 1
Trigger Output 0°
Sig GND
Enable 2 (COM)
Ishare
Trigger In
Reserved
Notes
120V modules or Enable 1 (220) for 220V modules)
Normally closed / transistor on, opens in fault condition
Do not connect
Used for 2-phase / split phase configuration
Only used on 120VAC units, connect to B2 to enable
Used for 3-phase configurations
Normally open / transistor off, closes in fault condition
Only used on 220/230VAC units, connect to B2 to enable
Used in hot-plugging, connect to D2 to enable
Used for single phase configuration
Tied internally to positive input, only use for LPE to LPE connections
Do not connect
Table 1 - Rear Connector Pinouts
(Mates with FCI P/N 51915-016)
Figure 2: LPE Rear Connector View
INSTALLATION
It is preferred to utilize TDI Power’s Hot Swap Shelf for the LPE500, the LPES1500, in which case
installation of the LPE consists of sliding the module into a bay in the shelf and locking it into place with
the folding handle. LPES Series Shelves are described on Page 13.
800586001 Operation Manual Rev A
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LPE Series
LPES Series Shelves
INTRODUCTION TO THE LPES SERIES
The LPES Series of shelves are the recommended method of mounting and connecting to LPE Series
Inverters. The LPES provides a secure mechanical mount, provides access to all input and output
power and signal connections, and provides all connections between modules to make installing a new
module as easy as inserting in into the shelf.
MECHANICAL
A full mechanical diagram of the LPES can be found in the Appendix B. The LPES meets all the EIA
standards for a 19” rack mount device. It is recommended to use #10-32 Truss head screws, 5/8 in.
long to mount the shelf on rails. The shelf material is cold rolled steel, with zinc plating with clear
chromate conversion coating per ASTM B 633-85 class FE/ZN8, type III. Inserts with a female #10-32
thread size are located toward the rear of the shelf on the sides for additional support if necessary.
ELECTRICAL
All electrical connections are made on the rear panel of the shelf. On the left side of the rear panel,
underneath a safety cover, two buss bars containing #10-32 threaded inserts are provided to connect
DC Power Input to the shelf. Use #10-32 screws or bolts 7/16” long to secure DC Input Power to these
connections via lugs. The shelf in turn connects this DC Input to the LPE modules.
DC-
DC+
DC Input Buss Bars
(cover removed)
AC power output is taken from a four position terminal block in the center of the rear panel. There are
two connections each for Line and Neutral. An 18 pin signal connector (pin out on Page15) is located
to the left of this terminal block. To the right of the terminal block there is an 8-32 threaded stud to
connect Earth Ground. To the left of the signal connector is a selector switch (120VAC/220VAC) which
should be set to match the type of modules to be mounted in the shelf. The purpose of this switch is to
prevent accidentally paralleling modules of different output voltages.
AC Output Terminal Block, Signal
Connector, and Grounding Stud
800586001 Operation Manual Rev A
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LPE Series
GROUNDING
1. The chassis ground terminals must be connected to safety ground.
The grounding strip shall withstand the rated inverter current.
2. The inverter input and output terminals are isolated from each other and from the inverter chassis.
For reliable and safe operation, please follow the grounding instructions below:
2a. Grounding on the output terminals: When left ungrounded, the output terminals (Line & Neutral)
have the same potential with respect to the inverter chassis (60VAC for 120V unit and
110VAC for 220V unit). It is customary in the United States, 120VAC distribution system, to
ground the neutral terminal. To minimize the local loop noise, it is recommended to ground the
neutral at the point of use. If required, the user can also connect the neutral output terminal to
the inverter chassis and safety ground.
2b. Grounding on the input terminals: The LPE inverter is designed to operate from either the
Negative or Positive ground bus. The most common applications are:
(i)
The telecom application with negative 48V bus, where the positive terminal is
grounded.
(ii)
The telecom application with positive 24V bus, where the negative terminal is
grounded.
There is no need to ground any of the input terminals if the unit is operating from a grounded
positive or negative bus. In applications where the input DC bus is floating, it is recommended to
ground the positive input terminal for 48V applications or negative input terminal for 24V
applications.
800586001 Operation Manual Rev A
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LPE Series
SIGNAL CONNECTOR PIN ASSIGNMENTS
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1-
FAULT _1_(+) (LEFT, when viewed from front of rack)
2-
FAULT _2_(+) (CENTER)
3- FAULT _3_(+) (RIGHT, when viewed from front of rack)
4- N/C
5- TRIG_IN
6- N/C
7- TRIG_120 (LEFT, when viewed from front of rack)
8- TRIG_120 (CENTER)
9- TRIG_120 (RIGHT, when viewed from front of rack)
10- FAULT_COM_(-)
11- FAULT_(+)
12- SIG_GND
13- N/C
14- I_SHARE
15- REMOTE (+)
16- N/C
17- REMOTE (-)
18- N/C
Remote (+/-) accepts either dry contact or open collector switching. This signal is referenced to the DC
input side, but should never be connected externally to either leg of the DC input. Connect these pins
(to each other) to Enable the modules, disconnect these pins to disable the modules.
FAULT signal pins connect to the Collector and Emitter of the transistor side of an opto-coupler. This
provides an optically isolated open collector type signal. Low impedance between these pins indicates
a fault.
FAULT : Low impedance between these and the FAULT_COM pin indicates “Output Good”
800586001 Operation Manual Rev A
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LPE Series
APPENDIX A
LPE OUTLINE DRAWING
LPE Side View
LPE Top View
LPE Front View
800586001 Operation Manual Rev A
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LPE Series
APPENDIX B
LPES OUTLINE DRAWING
LPES1500 Rear View
LPES1500 Front View (Fully Populated)
LPES1500 Side View
800586001 Operation Manual Rev A
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LPE Series
Revision History
Revision
A
B
C
P1
P2
P3
A
ECN #
Description of Change
Date
Change By
Initial Release
Initial Release
Initial Release
Incorporated additional
comments
Incorporated additional
comments
Incorporated additional
comments
Incorporated additional
comments
Unreleased
Unreleased
Unreleased
04-Apr-08
jjs
10-Apr-08
jjs
11-Apr-08
jjs
06-May-08
jjs
800586001 Operation Manual Rev A
Checked By
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